Modular Linear Press Actuator for High-Speed and High-Force Forming
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Solution Overview
Problem
Large press machines face productivity limitations due to the inability to simultaneously achieve high-speed and high-torque conditions necessary for forming parts, and they often suffer from issues like temperature dependency and messiness of hydraulic fluids, as well as mechanical complexities with crankshafts.
Innovation Solution
A press machine utilizing a planetary gear system driven by two motors, one for high-speed and one for high-force conditions, allowing for efficient linear actuation of a press ram to form parts with improved productivity while avoiding hydraulic and crankshaft-related problems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a single motor is used to drive the press ram, then the motor must provide both high speed and high torque, but no commercially available motor can deliver both conditions simultaneously
Solution Approach 1:
The drive system is segmented into two separate motors: a high-speed motor for advancing and retracting the press ram, and a high-torque motor for forming the part. This segmentation allows each motor to be optimized for its specific function rather than requiring a single motor to provide both high speed and high torque simultaneously.
Solution Approach 2:
The system dynamically switches between different motor configurations based on operational requirements. During advancement and retraction phases, the high-speed motor operates with minimal load. During the forming phase, the high-torque motor engages to provide the necessary force. This dynamic operation resolves the contradiction between speed and force requirements.
2Force
If hydraulic actuators are used to deliver high forces, then acceptable speed and productivity are achieved, but temperature dependency and fluid leaks occur
Solution Approach 1:
The patent replaces the hydraulic actuation system with a direct mechanical drive system using two motors coupled to the press ram through a mechanical transmission mechanism. This substitution eliminates the need for hydraulic fluid, pumps, valves, and filters, thereby eliminating temperature dependency and fluid leak problems while maintaining reliable high-force delivery during the forming operation.
3Force
If crankshafts are used to drive the press ram, then high forces are achieved, but mechanical complexity and maintenance requirements increase
Solution Approach 1:
The patent extracts and eliminates the complex crankshaft mechanism from the press drive system. Instead of using a crankshaft with bearings, lubrication systems, and counterbalance mechanisms, the invention uses a simplified direct mechanical drive system with two motors that couple directly to the press ram through a mechanical transmission, thereby reducing device complexity and maintenance requirements while maintaining high-force capability.
4Force
If a motor is selected for high torque, then high force is achieved, but rotational speed is limited and productivity decreases
Solution Approach 1:
The drive system is segmented into two separate motors: a high-speed motor for advancing and retracting the press ram, and a high-torque motor for forming the part. This segmentation allows each motor to be optimized for its specific function rather than requiring a single motor to provide both high speed and high torque simultaneously.
Solution Approach 2:
The system maintains continuous productive action by having the high-speed motor continuously advance and retract the press ram while the high-torque motor engages only during the brief forming operation. This continuous cycle of advancement, forming, and retraction maximizes productivity by minimizing idle time while ensuring high-force delivery when needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables high-force and high-speed operations, increasing productivity and reducing the drawbacks of hydraulic presses and crankshaft-driven systems by using a dual-motor planetary gear system for efficient part formation.
Implementation Method 1
The planetary gear system includes a ring gear, a sun gear, and a plurality of planet gears between the sun gear and the ring gear. The planetary gear system has an output shaft that is coupled to the linear actuator. A first motor is coupled to the planetary gear system for producing a high-speed condition on the linear actuator. A second motor is coupled to the planetary gear system for producing a high-force condition on the linear actuator.
Implementation Method 2
The planetary gear system provides mechanical advantage to convert rotational motion into linear motion with amplified force, allowing the press machine to achieve both high-speed and high-force conditions through coordinated operation of two motors.
Implementation Method 3
The linear actuator has a male-female screw arrangement and an actuator rod that is threadably coupled to the male-female screw arrangement. The actuator rod undergoes linear movement in response to rotational movement of the male-female screw arrangement.
Data Source
AI summary
A linear-actuated press machine comprises a press ram with a tool, a first linear actuator having a first actuator rod, a second line actuator having a second linear actuator rod, a high-speed motor coupled to the first linear actuator for providing a high-speed condition on the press ram, a first high-torque motor coupled to the first linear actuator, and a second high-torque motor coupled to the second linear actuator. The press machine (i) advances the tool toward the part by operation of the high-speed motor associated with the first linear actuator, (ii) forms the part with the tool by simultaneous operation of the first high-torque motor associated with the first linear actuator and the second high-torque motor associated with the second linear actuator, and (iii) retracts the tool from the part by operation of the high-speed motor associated with the first linear actuator.